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Related Manuals for Airlocker RD123
Summary of Contents for Airlocker RD123
- Page 1 RD123 MAZDA 8”, REAR AIR OPERATED LOCKING DIFFERENTIAL INSTALLATION GUIDE...
- Page 2 No liability is assumed for damages resulting in the use of the information contained herein. ARB Air Locker Locking Differentials and Air Locker are trademarks of ARB Corporation Limited. Other product names used herein are for identification purposes only and may be trademarks of their respective owners. ARB 4x4 ACCESSORIES Corporate Head Office 42-44 Garden St...
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Page 3: Table Of Contents
Table of Contents: 1 Introduction 1.1 Pre-Installation Preparation 1.2 Tool-Kit Recommendations 2 Removing the Existing Differential 2.1 Vehicle Support 2.2 Differential Fluid Drain 2.3 Removing the Axles and Differential 2.4 Marking the Bearing Caps 2.5 Checking the Current Backlash Amount 2.6 Spreading the Differential Housing 3 Bench Measurement 3.1 Approximate Backlash Shimming... -
Page 5: Introduction
1 Introduction IMPORTANT : BEFORE ATTEMPTING TO DISMANTLE YOUR VEHICLE FOR THIS INSTALLATION, PLEASE READ THIS INSTALLATION GUIDE IN ITS ENTIRETY, AS WELL AS ALL APPLICABLE SECTIONS OF YOUR VEHICLE MANUFACTURER’S SERVICE MANUAL. Pre-Installation Preparation This booklet is to be used in conjunction with your vehicle manufacturer’s service manual. -
Page 6: Tool-Kit Recommendations
1 Introduction Tool-Kit Recommendations Below is a list of tools and supplies you may need to complete this installation. Requirements for your vehicle may vary. Please consult your vehicle service manual for additional recommendations. Tools 1.2.1 Standard automotive sizes (metric and/or imperial) of sockets, wrenches, Allen keys, and drills. -
Page 7: Removing The Existing Differential
2 Removing the Existing Differential Vehicle Support Safely secure the vehicle on a hoist. We recommend supporting the vehicle on a chassis hoist to keep the differential area at a convenient working height and to leave the wheels and axles free to be rotated and removed. -
Page 8: Marking The Bearing Caps
2 Removing the Existing Differential Marking the Bearing Caps Using a pointed center punch, gently mark the differential housing and the bearing caps in a way that will enable you to correctly position the cap during reassembly. (Fig.1.) Figure 1. Checking the Current Backlash Amount IMPORTANT: This step is a precautionary measure recommended by ARB due... - Page 9 2 Removing the Existing Differential Set a depth indicator on one of the ring gear teeth as in Figure 2. Figure 2. While supporting the pinion gear by holding the drive shaft, rotate the differential in both directions while observing the maximum variation in depth from the indicator (i.e., the highest value minus the lowest value).
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Page 10: Spreading The Differential Housing
2 Removing the Existing Differential Spreading the Differential Housing IMPORTANT: Spreading the differential housing with a differential case spreader is a step which is critical to set up bearing pre-load when a differential is installed. Improper pre-load will result in undue bearing wear, increased stresses in the differential center, increased running noise, and ultimately, ring and pinion gear damage. -
Page 11: Bench Measurement
3 Bench Measurement Approximate Backlash Shimming In order to reproduce a similar pre-load and ring and pinion backlash in your Air Locker to that of your original differential, measurements need to be taken so that a shim thickness can be calculated. ... - Page 12 3 Bench Measurement Using a caliper or similarly accurate measurement method (i.e., able to take accurate measurements within 0.04mm [0.0015”]), measure the distance from the shoulder of the bearing journal to the ring gear mounting face (shown as ‘A’ in Fig.4.) and record this measurement as ‘A’.
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Page 13: Calculation & Selection Of Shims
3 Bench Measurement Calculation & Selection of Shims Ideally, the measurement you recorded as ‘C’ from the Air Locker differential will closely match ‘A’ on the existing differential (within 0.1mm [0.004”] ) and then the factory shim can be reused, however, quite often these measurements will vary slightly between one factory differential and the next. -
Page 14: Installing The Air Locker
4 Installing the Air Locker Installing the Carrier Bearings With the Air Locker well supported in an arbor press, apply a thin film of high pressure grease to both bearing journals. Press one of the tapered roller bearing cones onto one of the bearing journals of the Air Locker until the bearing seats firmly against the bearing journal shoulder. -
Page 15: Assembling The Seal Housing
4 Installing the Air Locker NOTE : Avoid using the bolts to pull down the ring gear as this puts excess strain on the bolts and the differential flange. Apply a thread locking compound to the thread of each ring gear bolt before inserting it. -
Page 16: Calculation & Selection Of Pre-Load Shims
4 Installing the Air Locker Make sure the grooves and airway of the seal housing are clean and free from any contaminants (e.g. water, dirt, metal filings, etc.). Inspect the seal housing O-rings (supplied) for dirt, damage or other conditions which might cause leaks. -
Page 17: Drilling And Tapping The Bulkhead Port
4 Installing the Air Locker Figure 7. PRE-LOAD + END FLOAT = SHIM PACK Select suitable shims from the shim kit supplied with your Air Locker to make up a shim pack of this thickness. (Refer to section 3.2 for methods of shim adjustment). Drilling and Tapping the Bulkhead Port An air line port must be drilled and tapped through the differential housing to mount the bulkhead fitting into. - Page 18 4 Installing the Air Locker Figure 8. Remove the Air Locker from the differential housing. Cover the drive pinion area with a rag to protect it from metal filings. Secure the differential housing to the work bench. ...
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Page 19: Modifying The Bearing Cap
4 Installing the Air Locker Tap the hole from the outside using ¼”NPT thread tap. Remove any sharp edges that may chip off from around the hole and fall into the housing. Very carefully, remove the rags and inspect with a service light inside the housing to insure no metal filings are left behind. -
Page 20: Final Air Locker Assembly
4 Installing the Air Locker Final Air Locker Assembly Spread the differential housing again (Refer to section 2.6). Hold shim packs ‘D’ (Refer to section 3.2) and ‘E’ (Refer to section 4.4) in position on the Air Locker. ... -
Page 21: Profiling The Seal Housing Tube
4 Installing the Air Locker Refer to your vehicle service manual for the specified maximum and minimum amounts of backlash. If the backlash is not within the specifications then the differential will have to be removed and re- shimmed. Re-Shimming the Backlash 4.8.1 NOTE :... - Page 22 4 Installing the Air Locker Figure 12. Figure 13. Check that the contour of the tube will not interfere with the Air Locker or the ring gear. The tube should be approximately 10mm [3/8”] from the ring gear so as to provide adequate clearance from the ring gear and also avoid contacting the axle assembly.
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Page 23: Setting Up The Bulkhead Fitting
4 Installing the Air Locker Setting up the Bulkhead Fitting 4.10 Apply thread sealant to the threads of the bulkhead body. Screw the bulkhead body into the tapped hole, and tighten. Wipe the area clean of any excess thread sealant (inside and outside of the housing). -
Page 24: Bench Testing The Air Locker
4 Installing the Air Locker Again check that no part of the seal housing tube comes in contact with the moving differential components. 10mm [3/8”] should be considered adequate clearance. Gently bend the tube away from moving parts if necessary. Bench Testing the Air Locker 4.11 ... -
Page 25: Reinstalling The Differential And Axles
4 Installing the Air Locker Reinstalling the Differential and Axles 4.12 This vehicle is fitted with Semi-Floating Axles. As such, a thrust block (supplied with the Air Locker kit) must be inserted into the differential center before installing the Air Locker into the axle housing. HINT : A wad of thick grease on the thrust block should keep it from sliding around during installation. -
Page 26: Installing The Air System
Installing the Air System Mounting the Solenoid Connection to an ARB Air Compressor 5.1.1 (Fig.16.) Remove one of the 1/8” BSP plugs from its port in the compressor tank. Apply Teflon paste to the nipple (1/8” X 1/8” BSP) and insert it into the port and tighten. - Page 27 Installing the Air System Connection to an Alternate Air Source 5.1.2 For ease of installation, quality of air supply, and a high level of dependability from your Air Locker(s) , ARB strongly recommends use of a genuine ARB Air Compressor, however, the Air Locker air system can be operated on any alternate air source that meets each of the following guidelines: ...
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Page 28: Running & Securing The Air Line
Installing the Air System Running and Securing the Air Line The path taken by the air line from your air source (i.e., compressor) to your Air Locker is unique to your vehicle and the position of your air source. Plan ahead carefully when running the air line and always follow these guidelines: ... -
Page 29: Connection To The Bulkhead Fitting
Installing the Air System Connection to the Bulkhead Fitting Trim the air line to length using a sharp knife. Insert the support spring over the end of the air line - small end first. (Fig.17.) Insert the outer compression nut over the air line. ... -
Page 30: Mounting & Connecting The Electrical System
6 Mounting & Connecting the Electrical System Mounting the Actuator Switch(es) Air Locker actuator switch(es) can be easily panel mounted inside the vehicle in a 21mm x 36.5mm [0.83” x 1.44”] rectangular cutout. NOTE : Only attach the cover plate to the face of the switch once the switch has been mounted and wired correctly as the cover plates are designed to be difficult to remove. -
Page 31: Wiring The Actuator System
6 Mounting & Connecting the Electrical System Figure 18. Wiring the Actuator System Connection to an ARB Air Compressor 6.2.1 When wiring the Air Locker actuator switch(es) and solenoid(s) to an ARB Air Compressor, all connections can easily be set up directly from the supplied wiring loom. - Page 32 6 Mounting & Connecting the Electrical System ARB AIR COMPRESSOR WIRING LOOM Figure 19. NOTE : ARB wiring loom #180405 shown. Consult the compressor installation guide for the diagram to suit your compressor model. SWITCH TERMINAL IDENTIFICATION Figure 20.
- Page 33 6 Mounting & Connecting the Electrical System Connection to an Alternate Air Source 6.2.2 When connecting the actuation switch to an alternate air source, the switch(es) should be wired according to Figures 21. and 22., depending on whether one or two Air Lockers will be installed in the vehicle.
- Page 34 6 Mounting & Connecting the Electrical System Dual Air Locker System 6.2.2.2 If two Air Lockers are to be installed in the system, ARB recommends that the switches and solenoids be wired according to Figure 22. For safety reasons, this configuration allows SOLENOID 2 to be actuated only if SOLENOID 1 is already on.
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Page 35: Testing & Final Assembly
Testing & Final Assembly Leak Testing With the vehicle parked and the engine off, turn the compressor on and wait until the air system is fully charged. NOTE : With the Air Locker(s) disengaged, the air source (i.e., compressor) should not have to recharge over time. Intermittent recharging without Air Locker use usually indicates a leak at the solenoid fittings or at the compressor tank O-ring seal. -
Page 36: Filling The Differential
Testing & Final Assembly Rotate one wheel by hand. The wheel should rotate freely and the opposite wheel should be turning in the opposite direction without any resistance or mechanical noise from within the differential. Turn the Air Locker switch to the ‘ON’ position. The illuminated symbol on the switch cover should light up. -
Page 37: Post-Installation Check List
Testing & Final Assembly Post-Installation Check List Now that the Air Locker installation has been completed, ARB recommends that you take the time to complete the following check list just to insure that you haven’t missed any of the vital steps. ... - Page 38 Testing & Final Assembly...
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Page 39: Parts List
Parts List Exploded Assembly Diagram (See itemized parts list overleaf Figure 23. -
Page 40: Itemized Parts List
Parts List Itemized Parts List (See exploded diagram figure 23.) RD123 AIR LOCKER MODEL No. : ITEM # DESCRIPTION PART # FLANGE CAP ASSEMBLY 028508 BONDED SEAL 160701 CLUTCH GEAR 050803 RETURN SPRING 150107 SPIDER BLOCK 070503 THRUST BLOCK 110505...
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